EP0804982B1 - Procédé de préparation d'ébauches de mousse métallique - Google Patents

Procédé de préparation d'ébauches de mousse métallique Download PDF

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Publication number
EP0804982B1
EP0804982B1 EP97890073A EP97890073A EP0804982B1 EP 0804982 B1 EP0804982 B1 EP 0804982B1 EP 97890073 A EP97890073 A EP 97890073A EP 97890073 A EP97890073 A EP 97890073A EP 0804982 B1 EP0804982 B1 EP 0804982B1
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EP
European Patent Office
Prior art keywords
chamber
foam
mould
process according
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP97890073A
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German (de)
English (en)
Other versions
EP0804982A2 (fr
EP0804982A3 (fr
Inventor
Frantisek Dr.-Ing. Simancik
Franz Dipl.-Ing. Schörghuber
Erich Ing. Hartl
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
USTAV MATERIAELOV A MECHANIKY STROJOV SLOVENSKEJ A
Original Assignee
Neuman AG
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Publication date
Application filed by Neuman AG filed Critical Neuman AG
Priority to NO972810A priority Critical patent/NO972810L/no
Publication of EP0804982A2 publication Critical patent/EP0804982A2/fr
Publication of EP0804982A3 publication Critical patent/EP0804982A3/fr
Application granted granted Critical
Publication of EP0804982B1 publication Critical patent/EP0804982B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/11Making porous workpieces or articles
    • B22F3/1121Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1125Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the invention relates to a method for casting molded parts made of metal foam, for example aluminum foam, the by powder metallurgy by foaming a particular to a semi-finished product, such as rods, pipes or granules compacted mixture of gas-releasing propellant with metal powder as the starting material under the influence of heat is formed.
  • the invention also relates to a device for performing the method.
  • Light metal fittings can be used as solid castings, as hollow bodies or also be designed as a metal foam body. While in the former category on the same as possible and thin wall thicknesses and the avoidance of local material accumulations to be observed, required hollow body mostly expensive casting cores, which complicate the production.
  • a modern alternative is achieved using metal foam casting.
  • the cast skin forms a smooth outer surface of the cast product, its interior is loosely filled with a pore structure is. The is suitable for a large number of application areas Metal foam casting, which results in a particularly light end product that leads to good sound insulation and low thermal conductivity offers. The strength properties are surprisingly high. Still, not every machine part can do this Casting technology can be produced.
  • powder metallurgical metal foam is produced according to DE 41 01630 C2 from metal powder and a gas-releasing Propellant.
  • the material is hot compacted and subjected to a change in shape.
  • the semi-finished product is e.g. in a heated steel mold due to the effects of temperature brought to frothing, the metal foam the Fills out the form gradually.
  • the disadvantage is that the Contour of the semi-finished product correspond to the contour of the mold cavity must, otherwise there is no even foaming. If you use rod-shaped primary material, then this must be exact cut to length and placed in the form. It can also cold welds between the foamed bars form.
  • a foam produced by melt metallurgy is already working into the state of the pores collapsing when after its manufacture is pressed into the mold. Often heated molds used, but their temperature does not increase may be high, otherwise the metal foam in reinforced Dimensions collapsed. The pores fall during foam production also uncontrollable and in different sizes. in the in general, this method only allows the production of simple mold parts. Furthermore, in the case of smelting metallurgical Procedure requires an agitator, positioning the stirrer in the melt is extremely problematic. The foam is only created in the area of the by the agitator Stirrer, so that the foam already produced during production of the foam still required during the stirring time collapsed. In addition, the amount of foam required is not exactly adjustable, so that the same parts do not match To have weight. The pores created have no internal overpressure, so that it is compressed when pressed into the form become. This results in an inconsistent structure.
  • DE 44 24 157 A describes a method for producing a porous metallic material with anisotropic properties described in which a foamed and porous metal foam plastically deformed with isotropic properties becomes.
  • the invention aims to provide a method that the production of contoured, three-dimensional molded parts of high quality. Uniform pores and a uniform, homogeneous surface and the possibility influencing the pore size and density as well the surface and its layer thickness are desirable parameters in the manufacturing process.
  • foam can be formed at best to be dispensed with in the mold. It is according to a training course of the method advantageous if the chamber with the foam-forming starting material compared to the mold in the type of a rotary drum furnace rotated and, if necessary, for Emptying is tipped into the mold. This will make the mold filled by the inherent pressure of the foam material. Especially It is advantageous if the metal foam in the chamber is pressed into the mold by a piston. The Koiben speed and the pressure form additional criteria for that Appearance of the molded part, both in terms of its Surface as well as the pore shape and density. The bringing in the resulting metal foam can also be made that the metal foam through a non-metal foam melt e.g.
  • To the non-metallic melt is introduced into the chamber or pushed in. This lifts the metal foam directly or a floating piston plate completely into the Mold.
  • the one carrying the metal foam Melt specifically heavier than the parent metal of the Foam and the melting point is lower (e.g. zinc or Tin and aluminum).
  • Findings in metal foam casting processes was recognized that Excellent results can be achieved when powder metallurgically formed metal foam into a non-metallic Mold, e.g. a sand mold is pressed.
  • sand mold In contrast to a steel mold, sand mold carries the heat of the introduced metal foam during the filling process not immediately so that the foam phase is retained until the remote ones Moldings are filled. In addition there is the supportive Effect due to residual foam formation in the mold. The foam is still active Phase into the form and contributes to the essential quality improvement at.
  • the semi-finished product is required. It should large temperature gradients in the chamber are avoided and the foam formation should by rapid heating of the chamber in Edge area of the chamber as well as inside if possible at the same time respectively. This is achieved in that a tubular or pipe socket-shaped semifinished product introduced into the chamber becomes. It is useful if this is as small as possible Play to the inner wall of the chamber, i.e. in thermal connection is provided to the wall in the chamber.
  • the heater can electrically, for example inductively. eddy currents and skin effect of inductive heating must be taken into account.
  • the inductive heating leads in connection with a tubular semi-finished products for the best foam quality.
  • An independent one Transfer the foam from the chamber to the mold is achieved at the right time by the semi-finished tube at least in the final phase of the heating process against the piston with a defined and adjustable force the nozzle plate is pressed so that the injection process is introduced into the form as soon as the semi-finished product Melting point reached and thus foamed.
  • the heating or a Preheating the semi-finished product is carried out under protective gas and preferably if the chamber is flushed with protective gas.
  • a device for Carrying out the method is characterized in that the chamber of a jacket for externally heated, non-metallic foam Melt for heating the chamber is surrounded.
  • the for The melt used to heat the chamber is in a separate Oven heated.
  • the chamber for powder metallurgy Semi-finished product a large temperature volume evenly be fed.
  • the device can be automated by that one or more chambers on a sled or carousel arranged and from a loading or cleaning position in the heating position for the loaded semi-finished product slidable in relation to a connection to a mold or are rotatable.
  • Fig. 1 shows an oven with a chamber and a mold before the start of foaming
  • Fig. 2 the arrangement after 1 after transfer of the metal foam into the mold
  • 3 shows an alternative embodiment of the arrangement, another alternative analogous to Fig. 1.
  • Fig. 5 another Embodiment
  • Fig. 6 is a multiple execution.
  • Fig. 7 an embodiment with a heating variant
  • Fig. 8 a Version with sliding chambers.
  • a chamber 2 for receiving a powder metallurgical starting material 3. These are compact semi-finished products, for example around wire pieces or pipe pieces made of metal powder and one Blowing agents that are exposed to the appropriate temperature form a metal foam.
  • a mold 4 With the chamber 2 is a mold 4 via a nozzle 5 in the manner of a perforated diaphragm for setting the gate for the casting in connection.
  • a piston 6 is guided in the chamber 2.
  • chamber 2 By increasing the temperature in oven 1 to about 500 to 600 ° C arises in chamber 2 from, for example, according to the EP 460 392 A1 manufactured semi-finished product, for example aluminum Pieces of wire, an aluminum foam, made with the help of the piston 6 completely and completely transferred into the mold 4 will (Fig. 2).
  • the chamber 2 is emptied and can then be new filled with semi-finished products as the starting material for foam formation be filled with the volume of the cast body is precisely coordinated.
  • the foam formation continues depending on the selected time the transfer from chamber 2 using the piston still in the mold 4.
  • the mold's existing foaming capacity is along with the volume of the semi-finished product used, its consistency and the Temperature profile during foaming and cooling an essential parameter for the structure of the foam part.
  • the mold is for cooling taken out of the oven 1. This will cause a collapse the foam pores are prevented due to excessive heat input.
  • the Casting 9 can be demolded and the chamber 2 in furnace 1 with a new shape. It can be done after a cleaning cycle a steel mold can also be used repeatedly.
  • FIG. 4. 4 a chamber 2 is shown, which has an inductive heating 7 has.
  • a furnace 1 that houses the entire arrangement is not available here.
  • the mold 8 is unheated.
  • a sand mold is advantageously used.
  • Foaming takes place analogously in FIG. 4 in chamber 2 to Fig. 1.
  • the foam is through the piston 6 into the mold 8 (sand mold) pressed. This takes place in contact between Metal foam and the wall of the mold, namely the Sand, just a little heat removal, so that the metal foam maintains its viscosity and in every last corner of the Mold arrives.
  • the one specifically continued in the mold Foaming supports this effect. It can be on this Also very complicated castings with narrow ribs, Undercuts or the like can be produced.
  • the unheated sand mold 8 shown in Fig. 4 solves the Problems. It can be any non-metallic form, including one Ceramic or plaster mold used with the advantages mentioned become.
  • FIGS. 1 and 2 show an alternative to FIGS. 1 and 2.
  • the Nozzle 10 and mold 11 is rotatable over and over two separate heaters 12, 13 arranged the separately can be regulated or switched on and off.
  • a drive 14 with a bearing 15 stands the piston rod 16, the is designed as a bearing on the other side.
  • the process proceeds as described for FIGS. 1 and 2 is.
  • the rotation homogenizes the powder metallurgical Foam formation in the chamber 2 and also in the mold 11.
  • the latter can be used in the sense of the explanations for FIG. 4 as non-metallic Mold remain unheated. It is also possible, to arrange only the chamber 2 or only the mold 11 rotatably.
  • Fig. 4 which is a further development for execution Fig. 4 is in the chamber 2 as a powder metallurgy Starting material a tubular semifinished product 3 'on a Cutting disc 20, for example made of titanium or ceramic, is provided.
  • the tubular semi-finished product 3 ' is made by inductive Heater 21 heated evenly, so that foam formation also is done very evenly and homogeneously.
  • the foam as Contents of the chamber 2 floats according to FIG. 5 - with an intermediate layer the cutting disc 20 on a "liquid piston", the is formed by a zinc, tin or lead melt.
  • To the tub 22 is kept at the melting temperature (heating not shown).
  • a piston 23 depresses the melt, whereby the cutting disc 20 is raised and the foam content the chamber 2 is pressed into the form 8.
  • FIG. 6 shows a multiple application of modules according to FIG. 4 or 5.
  • One or - as shown in Fig. 6 two forms 24, 25 (possibly more) of a plurality fed by heated chambers 2 'with metal foam.
  • the single ones Chambers 2 ' can be inductively heated and the formed Metal foam synchronously or via a control Feed into the mold or molds with a time delay.
  • Foam formation in the chamber or chambers according to FIG. 1 to 6 can also take place according to FIG. 7 in that the chambers 2 or the chambers of a jacket made of non-metallic foam Melt 26 is or are surrounded for heating.
  • the Melt 26 is heated in an oven 27. It follows an ideal heating condition due to the large heat potential of the melt of the powder metallurgical semi-finished product, whereby the Uniformity of frothing and the frothing time positive to be influenced.
  • the shape of the semi-finished product is particularly important.
  • Another variant of the invention is that in the chamber 2 inserted semi-finished tube 3 'through the piston 6 to press against the nozzle plate 5 with a defined force. As soon as the semi-finished product reaches the melting point and thus starts to foam, it loses its firmness and the Piston 6 can press the processed foam into the mold. It may be appropriate to apply the force to the piston and thus the shooting speed of the foam into the form 8 too change as soon as the piston 6 starts to move.
  • This Measure results in a very simple control of the system is capable of any scatter, for example in the preheating temperature of the semi-finished product, in its heating rate or even in the melting point of the semi-finished alloy, since only that for the injection time A corresponding viscosity of the foam melt is reached is decisive and all other parameters are disregarded stay.
  • This measure is very simple achieved a very even foam formation. It is also much easier, the system on another foam casting switch, since the otherwise very complex Optimization of the production parameters considerably simplified and changeover times can be drastically reduced.
  • FIG. 8 shows another alternative with several chambers 2 ', 2 ", which are electrical here, for example, according to FIG. 7
  • For injection of the foam formed by powder metallurgy moves rotatable part additionally in the axial direction, so that the chamber 2 "directly connects to the (divided) form 4.
  • the horizontal arrangement of the chambers 2 ', 2 " is advantageous because the piston 6 'is not in during foaming heated area and therefore only a small one Subject to temperature stress.
  • the device can have two or more chambers 2 ', 2 ", the two or more Take positions (e.g. separate cleaning, loading with semi-finished products, heating and injecting). There can be a revolver or carousel construction with several stations, however also a linear shift back and forth using a Carriage construction may be provided.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Cell Electrode Carriers And Collectors (AREA)

Claims (14)

  1. Procédé pour couler ou mouler des pièces moulées en mousse métallique, par exemple en mousse d'aluminium, formée par la voie de la métallurgie des poudres par moussage, sous l'action de la chaleur, d'un mélange compacté de combustible libérant du gaz avec de la poudre métallique, en particulier sous la forme d'un demi-produit tel que des barres ou des tubes ou de granulats, et servant de matériau de départ, procédé dans lequel le moussage est réalisé dans une chambre susceptible d'être chauffée et qui est située à l'extérieur d'un moule de coulée, dans lequel procédé le volume du matériau de départ, en particulier sous forme de demi-produits, à poudre métallique placé dans la chambre susceptible d'être chauffée, dans sa phase mousseuse, avec sa capacité totale de formation de mousse, correspond sensiblement au volume d'un remplissage du moule de coulée, dans lequel procédé le contenu total de la chambre est refoulé par pressage dans le moule de coulée sous la forme de mousse métallique en fusion obtenue par la métallurgie des poudres, et dans lequel procédé le moussage est poursuivi avec le reste de la capacité de moussage jusqu'à obtenir le remplissage complet du moule de coulée et ensuite, la pièce moulée en mousse est refroidie, puis extraite du moule de coulée.
  2. Procédé selon la revendication 1, caractérisé en ce que la densité de la pièce moulée à fabriquer est réglable par l'intermédiaire du degré du remplissage de la chambre avec le matériau de départ, ou par l'intermédiaire du volume de la chambre.
  3. Procédé selon les revendications 1 ou 2, caractérisé en ce que la chambre remplie du matériau de départ formant une mousse, est mise en rotation par rapport au moule de coulée sous la forme d'un tambour tournant et qui, pour le vidage dans le moule de coulée, est poussée, le cas échéant, basculée.
  4. Procédé selon l'une des revendications 1 à 3, caractérisé en ce que la mousse métallique en fusion est pressée dans la chambre par un piston dans le moule de coulée, l'instant au cours du déroulement du procédé déterminant l'étendue de la capacité de moussage restante, et par voie de conséquence, la structure de la pièce moulée étant préselectionné.
  5. Procédé selon l'une des revendications 1 à 3, caractérisé en ce que la mousse métallique en fusion est soulevée et pressée dans le moule de coulée par un matériau en fusion, en particulier exempt de mousse métallique en fusion, par exemple par un sel en fusion, sur lequel est exercé une pression et sur lequel nage la mousse métallique obtenue par métallurgie des poudres, le cas échéant avec interposition d'une plaquette.
  6. Procédé selon l'une des revendications 1 à 5, caractérisé en ce que la mousse métallique en fusion est pressée dans un moule de coulée en matériau non-métallique, par exemple un moule en sable, un moule en céramique, un moule en plâtre ou similaire.
  7. Procédé selon l'une des revendications 1 à 6, caractérisé en ce que la mousse métallique en fusion est pressée à travers une buse entre la chambre et la cavité du moule.
  8. Procédé selon l'une des revendications 1 à 7, caractérisé en ce qu'on introduit dans la chambre un demi-produit de forme tubulaire ou en forme de raccord tubulaire.
  9. Procédé selon l'une des revendication 8, caractérisé en ce que le demi-produit de forme tubulaire ou en forme de raccord tubulaire est placé dans la chambre avec le plus faible jeu possible par rapport à la paroi intérieure de la chambre et le chauffage de la chambre est réalisé de préférence, électriquement; en particulier par induction.
  10. Procédé selon l'une des revendications 8 ou 9, caractérisé en ce que le demi-produit tubulaire est pressé au moins dans la phase terminale du processus de chauffage par le piston avec une force définie et réglable contre la plaque de buse, de sorte à déclencher le processus d'injection dans le moule, dès que le demi-produit atteint le point de fusion et de ce fait mousse.
  11. Procédé selon l'une des revendications 1 à 10, caractérisé en ce que pour la réduction des couches d'oxyde, on réalise un chauffage ou un préchauffage du demi-produit sous une atmosphère de gaz de protection et de préférence, on nettoie la chambre avec du gaz de protection.
  12. Procédé selon l'une des revendications 1 à 11, caractérisé en ce que la mousse en fusion obtenu par la métallurgie des poudres de plusieurs chambres qui sont couplées en parallèle, est pressée à travers plusieurs attaques de coulée dans la cavité d'un ou de plusieurs moules, de façon simultané ou selon un décalage temporel par l'intermédiaire d'une commande.
  13. Dispositif pour mettre en oeuvre le procédé selon l'une des revendications 1 à 12, comprenant une chambre 2 susceptible d'être chauffée et dans laquelle un piston (6) est susceptible de coulisser et à laquelle est raccordé un moule de coulée (8) pour recevoir la mousse d'aluminium à partir de la chambre (2), caractérisé en ce que la chambre (2, 2') est entourée d'une enveloppe pour matière en fusion (26) chauffée extérieurement et exempte de mousse métallique, pour chauffer la chambre (2,2').
  14. Dispositif pour mettre en oeuvre le procédé selon l'une des revendication 1 à 12, comprenant une chambre (2) susceptible d'être chauffée et dans laquelle un piston (6) est susceptible de coulisser et à laquelle est raccordé un moule de coulée (8) pour recevoir la mousse d'aluminium à partir de la chambre (2), ou bien d'après le dispositif selon la revendication 13, caractérisé en ce qu'une ou plusieurs chambres (2, 2') sont disposées sur un traíneau ou un carrousel et sont susceptibles de tourner ou de coulisser par rapport à un raccord à un moule dans la position de chauffage pour le demi-produit chargé, à partir d'une position de chargement ou de nettoyage.
EP97890073A 1996-04-19 1997-04-18 Procédé de préparation d'ébauches de mousse métallique Expired - Lifetime EP0804982B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NO972810A NO972810L (no) 1997-04-18 1997-06-18 FremgangsmÕte for fremstilling av formdeler av metallskum

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AT719/96 1996-04-19
AT71996 1996-04-19
AT0071996A AT406027B (de) 1996-04-19 1996-04-19 Verfahren zur herstellung von formteilen aus metallschaum

Publications (3)

Publication Number Publication Date
EP0804982A2 EP0804982A2 (fr) 1997-11-05
EP0804982A3 EP0804982A3 (fr) 1997-11-12
EP0804982B1 true EP0804982B1 (fr) 2002-11-27

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EP97890073A Expired - Lifetime EP0804982B1 (fr) 1996-04-19 1997-04-18 Procédé de préparation d'ébauches de mousse métallique

Country Status (5)

Country Link
US (1) US5865237A (fr)
EP (1) EP0804982B1 (fr)
JP (1) JPH1029052A (fr)
AT (2) AT406027B (fr)
DE (1) DE59708794D1 (fr)

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ATE228411T1 (de) 2002-12-15
DE59708794D1 (de) 2003-01-09
ATA71996A (de) 1999-06-15
US5865237A (en) 1999-02-02
AT406027B (de) 2000-01-25
EP0804982A2 (fr) 1997-11-05
EP0804982A3 (fr) 1997-11-12

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